Case studies Vertical bearing GGG40 (GJS )

Transcription

1

2 Vertical bearing GGG40 (GJS ) Machine: MC HSK63 Material: GGG 40 (EN-GJS ) Parts/Year: ca Pre-machining: boring Coolant : Minimum quantity lubrication (MQL) Ø 33N5 x 142mm MQL CircoTec RX W (RM) v c (m/min) f z (mm) v f (mm/min) a p (mm) Rz (μm) <10 <10 Results Reliable, accurate Bad tool life

3 Chain link MC tool magazine 2x Ø 26H6 x 21mm GAlSi12 CircoTec RX26 v c (m/min) 127 v f (mm/min) 1727 a p (mm) 0.20 Tool life (min) 180 Result Time saving High process reliability 10 times faster RX-geometry Cutting grade A01 F0510P

4 Pump housing Ø 100K7 GGG50 GJS CircoTec RX100 v c m/min) 207 v f (mm/min) 768 a p (mm) 0.20 Tool life (min) Result Time saving > 1 Year High process reliability 5 times faster

5 Pump housing Ø 20H7 RX-geometry (in both cases) Cutting grade A01 F0512R1 GGG50 GJS CircoTec RX20 v c m/min) 200 v f (mm/min) 3800 a p (mm) 0.10 Tool life (min) > 1 Year Result High process reliability

6 Vacuum pump cylinder bore (Page 1/2) Ø 68H8 x 70mm EN-GJL Ceramic guide pads

7 Vacuum pump cylinder bore (Page 2/2) Ø 68H8 x 70mm EN-GJL Material EN-GJL Insert RXG68H8-A01 F0512R1 Coating F0512R1 V c (m/min) 120 n (1/min) 562 f z (mm) 0,16 V f (mm/min) 1079 a p (mm) 0.09 Ra = 0.8 µm

8 Knuckle (wheel hub) (Page 1/2) Ø 75H7 x 54mm EN-GJS-500-7

9 Knuckle (wheel hub) (Page 2/2) Ø 75H7 x 54mm EN-GJL EN-GJS CircoTec RX75 v c (m/min) 150 v f (mm/min) 915 Rz (μm) < 10 RX-geometry Cutting grade A03 F0512R1 Tool life ~540 m Time saving 32%

10 Water pump (for Trucks) (Page 1/2) Ø and Ø 55 EN-GJL-250

11 Water pump (for Trucks) (Page 2/2) Ø and Ø 55 EN-GJL-250 GJL-250 CircoTec RX v c (m/min) 100 v f (mm/min) 1274 Rz (μm) < 10 Inserts RXG36.48-A01 F0514R2 RXG55-G01M2 F0514R2 Tool life parts Time saving 75%

12 Cylinderblock 2-stroke engine (Page 1/2) Ø /-8 x 80mm GAlSi4

13 Cylinderblock 2-stroke engine (Page 2/2) Ø /-8 x 80mm GAlSi4 GAlSi4 CircoTec RX 052 v c (m/min) 406 f z (mm) 0.18 v f (mm/min) 4320 a p (mm) 0.13 Ra (μm) 0.2 Geometry Cutting grade Tool life C17 F0510C > parts Advantages against PCD special tools: higher feed rates lower tool cost (coating against PCD) stronger and more stable cutting edges

14 Truck engine Valve bushing / ring seat (Page 1/2) Ø 16,49 x 95 and Ø 47,53 x 10mm EN-GJS

15 Truck engine Valve bushing / ring seat (Page 2/2) Ø 16,49 x 95 and Ø 47,53 x 10mm EN-GJS EN-GJS CircoTec RX 019 / 052 v c (m/min) 90 f z (mm) 0.23 v f (mm/min) 2400 a p (mm) 0.35 Geometry Cutting grade S05 F0508P2 Tool life pcs

16 Differential casing (Truck) Ø 36P7 x 47mm EN-GJS mm GJS CircoTec RX v c m/min) 127 v f (mm/min) 1727 a p (mm) 0.20 Tool life (min) 180 Result RX-geometry Coating High process reliability A01 F0522A Time saving 10 times faster

17 Brake caliper (Page 1/2) Ø 54H8 x 49mm GGG55 GGG55 CircoTec RX v c (m/min) 110 f z (mm) 0.25 v f (mm/min) 1622 a p (mm) 0.14 Time saving 50% Surface R z 30 R a RX-geometry Insert grade A03 F0508P2

18 Brake caliper (Page 2/2) Ø 54H8 x 49mm GGG55 GGG55 CircoTec RX v c (m/min) 110 f z (mm) 0.25 v f (mm/min) 1622 a p (mm) 0.14 Time saving 50% Surface RX-geometry Insert grade R z 30 R a A03 F0508P2 Tool life ~ pcs (1300 meters!) Time saving 50% Ra μm

19 Liner bore (crank-shaft) F1-motor 6x Ø 65H6 x 26mm EN-GJS and AluSil17 GJS / AluSil17 CircoTec RX81 v c (m/min) 150 v f (mm/min) 870 a p (mm) 0.25 Rz (μm) < 16 Tool life (min) ~200 RX-geometry Insert grade Special F0508P1 Time saving 11 times faster!

20 Hydraulic directional control valve Ø / x 90 mm (with 5 lands) GGG40 (QT450) CircoTec RX v c (m/min) 60 v f (mm/min) 1205 a p (mm) 0.30 Cylindricity (μm) <8 RX-geometry Insert grade Special F0512R1 Cylindricity < 8 μm Time saving 5 times faster! Tool life > parts (> 450 m)

21 (Page 1/2) Hydraulic directional control valve «Spool bore» Ø / EN-GJS

22 (Page 2/2) Hydraulic directional control valve «Spool bore» Ø / EN-GJS Nodular Cast Iron GGG40 / GJS 400 System RX29 v c (m/min) 90 f z (mm) 0.13 v f (mm/min) 1065 a p (mm) 0.15 Tool life (parts) 1200 Time saving (min/pce) 5.5 min. Cutting geometry Insert grade C01 F0512R1 Time saving 5.5 minutes/pce Tool life > parts

23 Hydraulic directional control valve «Spool bore» Ø / EN-GJS

24 Hydraulic directional control valve «Spool bore» Ø EN-GJS

25 (Page 1/3) Hydraulic directional control valve «Spool bore» Ø 75H6 x 435 mm EN-GJS Targets: - Be able to machine within the required tolerances! - Surface finish max. tol. Ra 0.8! - Roundness tol. max Availability of tools! (quick delivery of 7 prototype parts)

26 (Page 2/3) Hydraulic directional control valve «Spool bore» Ø 75H6 x 435 mm EN-GJS GJS RXG75H6-A01 Insert grade F0512R1 v c (m/min) 120 n (1/min) 510 f z (mm) 0,09 v f (mm/min) 550 a p (mm) 0.10 Piloting, 8mm deep

27 (Page 3/3) Hydraulic directional control valve «Spool bore» Ø 75H6 x 435 mm EN-GJS GJS RXG75H6-A01 Insert F0512R1 v c (m/min) 120 n (1/min) 510 / 200 f z (mm) 0,09 v f (mm/min) 550 a p (mm) 0.10 Ra = 0.45 µm Tolerance < mm Finishing (before honing)

28 Planet gear hub (Page 1/3) Ø 13.5N7 Steel and Sheet metal CircoTec RX configuration: SD-Steel shank Ceramic guide pads Integrated run-out compensation Internal coolant (insert and guide pads) Repeatability overall run-out <0.004mm

29 Planet gear hub (Page 2/3) Ø 13.5N7 Steel and Sheet metal Steel / Sheet metal Insert grade RXG13.5N7-D01 F0512R1 D (mm) 13.5N7 v c m/min) 144 v f (mm/min) 1020 a p (mm) 0.12 Rz (μm) < 16 Tool life (bores x2) >2900 Time saving 83%

30 Planet gear hub (Page 3/3) Measurable results: Tool life: 2900 bores (26m) Time savings: >83% (7 sec per part) equals to >4 800 hours per year! Non-measurable results: much easier to handle (required by Operators) remarkably less setup time!

31 Side wall (Textile machine) Ø 110K6 x 100mm EN-GJL-250 GG25 (GJL-250) CircoTec RXG v c (m/min) 140 v f (mm/min) 1070 a p (mm) 0.20 f z (mm) 0.22 RX-geometry Insert grade A01 F0514R1 10 times faster!

32 Steering arm (Textile machine) Ø 55K6 x 40mm EN-GJL-250 GG25 (GJL-250) CircoTec RXG v c (m/min) 160 v f (mm/min) 2032 a p (mm) 0.10 f z (mm) 0.22 RX-geometry Insert grade A01 F0512R1 29 times faster! (Compared to boring tools)

33 Bearing case Ø 80H7 x 77 mm EN-GJS Overhang (xs) 490 mm! GGG40 (EN-GJS ) CircoTec RXG v c (m/min) 120 (10)* v f (mm/min) 459 (48)* a p (mm) 0.15 f z (mm) 0.08 Ra (μm) 0.18 Tool life (min) >137 * for 3 mm entry RX-geometry Insert grade B07 T1500 Ra 0.18 μm

34 Guide tube for Shock absorber (Motorbike) Ø x 197mm Alu EN-AW-6082-T6 Aluminium EN-AW-6082-T6 CircoTec RXG v c (m/min) 392 v f (mm/min) 4989 a p (mm) 0.10 f z (mm) 0.20 Ra (μm) 0.17 Tool life (parts) >1500 Machine V-Turn 16 Lathe Ra 0.17 μm RX-geometry Insert grade S01 F0510C

35 Valve plunger guidebore (Marine Diesel) Ø 42H8 x 68 mm EN-GJL-250 Overhang 535mm! EN-GJL-250 CircoTec RX v c (m/min) 45 v f (mm/min) 819 a p (mm) 0.14 Rz (μm) < 16 Tool life (pcs.) 10 x more than with the actual reamer Time saving 95% 535mm RX-geometry Insert grade A01 F0512R1 Time saving 95% excellent tool life

36 Valve bushing seat (Plunger bore) Ø 45H7 x 73 mm EN-GJL-250 GJL-250 CircoTec RX v c (m/min) v f (mm/min) 2200 a p (mm) 0.15 Rz (μm) < 6.3 Profit 59.3% geometry Insert grade A01 F0512R1 Cost saving 59.3%

37 Cylinder block (4-cylinder) Ø 14H7 x 14 mm EN-GJL-250 Double-spindle horizontal HSK-100 MC Cast Iron 25 GJL-250 Geometry Insert grade RXG12.018Q+3-3 A01M2 F0512R1 v c (m/min) 115 f z (mm) 0.2 v f (mm/min) 3660 a p (mm) 0.1 Ra (μm) Max. 3.2 Tool live (parts) ~ 3500

38 Valve body Ø x 21 mm Material S300 6-spindles Index MS 42-C S300 RXG v c (m/min) 150 v f (mm/min) 2681 a p (mm) Ra (μm) 0.29 Tool life (parts) 4500 RX-geometry Coating A01 T1500

39 Cylinder block (axial piston pump) Ø x 21 mm EN-GJS GGG60 GJS CircoTec RX v c (m/min) 60 v f (mm/min) 546 a p (mm) 0.15 Time saving 50% RX-geometry Insert grade S08M1 F0514R1 Tool life > 267 m (500 pcs)! Ra μm

40 Cylinder block (axial piston pump) (Page 1/2) (Internal chip former test) 9x Ø 27H7 x 78 mm 42CrMo4+N+QT

41 Cylinder block (axial piston pump) (Page 2/2) Internal chip former test 9x Ø 27H7 x 78 mm 42CrMo4+N+QT (1.7225) 42CrMo4+N+QT Insert grade SRXG27H7-C (chip former) F0512R1 Vc (m/min) 140 n (1/min) 1650 fz (mm) 0.25 Vf (mm/min) 3301 ap (mm) 0.1 Rz (µm) 2.7 Result: short curled chips flowing backwards

42 Con-rods (Page 1/3) Ø x 28 mm 34 CrMo 4 (1.7220)

43 Con-rods (Page 2/3) Ø x 28 mm 34 CrMo 4 (1.7220)

44 Con-rods (Page 3/3) Ø x 28 mm 34 CrMo 4 (1.7220) 34 CrMo Insert grade RXG55+20-A01 F0514R1 v c (m/min) 150 f z (mm) 0.15 (0.12)* v f (mm/min) 1302 (209)* a p (mm) Rz (µm) Roundness (µm) * semi-finishing

45 Differential housing Ø H7 x 22 mm EN-GJS-500-7) GJS Insert grade RXG16.008H7-A01 F0512R1 v c (m/min) 110 f z (mm) 0.19 v f (mm/min) 2496 a p (mm) 0.1 R z max 25 μm Tool life > 6000 parts

46 Planet gear body Ø JS7, 2 x 26 mm EN-GJS ) Speroidal graphite iron (ADI) VISG600/5 Geometry Insert grade RXG36.3JS6 A01 F0508P v c (m/min) 140 f z (mm) 0.25 v f (mm/min) 2455 a p (mm) 0.15 Ra max. (μm) 1.2

47 Machine tool table (bearing positions) Ø EN-GJL-250) Cast Iron 25 / GJL 250 Geometry Insert grade RXG A01 A01 F0514R2 v c (m/min) 125 f z (mm) 0.15 v f (mm/min) 1150 a p (mm) 0.20 Tool life (parts) 3500 Time saving/part 1.5 min. Tool life > 3500 parts Time saving 1.5 min/part

48 Bearing housing (Machine tool part) Ø EN-GJL-250 Cast Iron GG25 / GLS 250 Geometry Insert grade System RX61 A01 F0514R2 v c m/min) 125 f z (mm) 0.13 v f (mm/min) 1065 a p (mm) 0.15 Tool life (parts) 1200 Time saving (1 tower, 6 parts) 4.8 min. Tool life > 1200 parts Time saving > 50 sec/part

49 Universal yoke Ø 24F7 x 15 Ck45 NHJ DBL (forged) Run-out of special tool: 3-5 µm RXG24F7-S02 HFS Insert grade T2000 v c (m/min) f z (mm/rev) v f (mm/min) a p (mm) Tool life (pcs) 8800 <5500 Remarks Chipflow problems Consistant tool life Easy handling